Key Planning Tips for Successful Roll Fold Projects

Roll fold designs are often used for advertising pieces and are meant to catch the eye of the consumer with the unique product design. There are several items to consider when planning for a roll fold product to ensure accurate registration and crisp folding results.

A good guideline to follow when planning for roll folds, is to realize that the outer two panels of the product should be the same size as the final required size of the piece, while the interior panels should be successively smaller in width by 3/32”, ending with the innermost panel 1/16” smaller in width that the panel immediately preceding it. This guideline will vary somewhat based upon the paper stock being used, with heavier basis weight stocks requiring slightly larger panel size reductions. If panel size decisions are not carefully planned, the end product may display wrap around registration issues and/or push-out problems.

Scoring of the panels is also a critical element toward achieving a crisp and registered folding result, particularly on basis weight stocks heavier than 80 lb. If a project requires scoring, verify the width of your folder, or your trade bindery’s folder, in comparison to the length of the sheet to be scored. If the material to be scored is longer (wider) than the folders capability, the printer must plan for die scoring of the flat press sheets. Failure to incorporate scores on heavier basis weight stocks can result in cracking and fold variation or skew in the final product.

Involving the Sales and Planning Professionals at Allied Bindery can help you with planning requirements for roll fold projects. Review of project trim size, number of panels, paper basis weight and design will result in a superior end product for your customer.